EP1436136B1 - Procede de revetement par extrusion de plusieurs bandes continues - Google Patents

Procede de revetement par extrusion de plusieurs bandes continues Download PDF

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Publication number
EP1436136B1
EP1436136B1 EP02801725A EP02801725A EP1436136B1 EP 1436136 B1 EP1436136 B1 EP 1436136B1 EP 02801725 A EP02801725 A EP 02801725A EP 02801725 A EP02801725 A EP 02801725A EP 1436136 B1 EP1436136 B1 EP 1436136B1
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EP
European Patent Office
Prior art keywords
webs
web
coating
polymer
extrusion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP02801725A
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German (de)
English (en)
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EP1436136A1 (fr
EP1436136A4 (fr
Inventor
Gary H. Knauf
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Thilmany LLC
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Thilmany LLC
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Publication date
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Publication of EP1436136A1 publication Critical patent/EP1436136A1/fr
Publication of EP1436136A4 publication Critical patent/EP1436136A4/fr
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00Processes for applying liquids or other fluent materials
    • B05D1/26Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • B05D1/265Extrusion coatings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07Flat, e.g. panels
    • B29C48/08Flat, e.g. panels flexible, e.g. films
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/88Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911Cooling
    • B29C48/9135Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00Sheets
    • B05D2252/02Sheets of indefinite length
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/30Extrusion nozzles or dies
    • B29C48/305Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00Layered products
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243Coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B43/00Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor
    • B32B43/006Delaminating
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H23/00Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/22Addition to the formed paper
    • D21H23/46Pouring or allowing the fluid to flow in a continuous stream on to the surface, the entire stream being carried away by the paper

Definitions

  • the invention relates to a method for making webs and, in particular, to a new method for extrusion coating multiple webs simultaneously on a dual or tandem extruder system having multiple extruder stations.
  • Webs such as paper and paperboard, polymer films, and metal foils which have been extrusion coated with a layer of polymer film are used in a myriad of applications such as packaging materials and so forth.
  • so called “tandem" or dual extruders have been developed with multiple extrusion stations.
  • Another object of the invention is to provide a method for producing extrusion-coated substrates at a higher production rate.
  • the present invention provides a method for extrusion coating multiple webs in an extruder system containing multiple extrusion stations as defined in appended claim 1.
  • the method includes feeding a first web and a second web into a first extrusion station in the extruder system, where each web has a coating side and an underside.
  • the webs are arranged one with respect to the other to form a temporary composite wherein respective undersides ofthe webs face each other and their respective coating sides face outwardly, away from each other.
  • a first polymer coating is extruded on the coating side of the first web at the first extrusion station.
  • the composite is fed to a second extrusion station following extrusion of the first polymer coating thereon.
  • a second polymer coating is extruded on the coating side of the second web of the composite.
  • the extrusion coated first and second webs are then separated.
  • first and second webs comprise the same or similar materials. However, in other embodiments it is preferred that the first and second webs comprise substantially different materials.
  • Preferred materials for the first and second webs include paper webs, polymer films, nonwoven fabrics, metal foils, and two or more thereof as a multi-ply web.
  • the first and second webs preferably each have a basis weight of from about 11.39 g/m 2 (7 lbs/3000 ft 2 ) to about 203.43 g/m 2 (125 lbs/3000 ft 2 ) and a caliper of from about 0.0127mm (0.5 mils) to about 0.254 mm (10 mils).
  • the first and second webs be extrusion coated with the same type of polymer. However in certain other embodiments, it may be preferred that the first and second webs are extrusion coated with different types of polymers.
  • the first and second polymer coatings comprise a polymer selected from the group consisting of low density polyethylene (LDPE), polyolefin plastomers (POP), polyolefin elastomers (POE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), polypropylene (PP), ethylene methyl acrylate copolymer (EMA), ethylene butyl acrylate copolymer (EnBA), ethylene vinyl acetate copolymer (EVA), ethylene acrylic acid copolymer (EAA), ethylene methyl acrylic acid copolymer (EMAA), ionomoers such as SURLYN, ethylene vinyl alcohol (EVOH), polyesters such as polyethylene terephthalate (PET), and polyamides (
  • LDPE low density polyethylene
  • the invention therefore enables use of a dual station extruder to provide webs which are extrusion coated only on one side.
  • the method of the invention essentially increases the production rate for such single-side coated webs by a factor of two or more.
  • the invention involves a method for extrusion coating multiple webs on dual tandem extruder systems having multiple extrusion stations.
  • the method includes as an initial step providing a first web and a second web wherein each of the first and second webs have a coating side and an underside.
  • the webs are superposed one with respect to the other to form a temporary composite wherein the respective coating sides face outward and the respective undersides face one another.
  • a first polymer coating is extruded on the coating side of the first web at a first extrusion station.
  • a second polymer coating is extruded on the coating side of the second web at a second extrusion station.
  • the extrusion coated first and second webs are then separated.
  • each extrusion station includes a hopper into which solid pellets of the polymeric coating material are feed, a heating zone wherein the polymer is melted prior to extrusion, and a slot or die through which the molten extrudate is feed and applied to the awaiting substrate web.
  • One such dual extruder is available from Egan-Davis Standard of Somerville, New Jersey.
  • a first web 10 and a second web 12 are supplied to a dual extruder, preferably from separate unwind stands 14, 16.
  • first web merely refers to the web which is coated with the first coating at the first extrusion station.
  • second web refers to the web which is coated with the second coating at the second extrusion station.
  • first substrate or web and second substrate or web are sometimes used in the extrusion coating art to designate the web from the unwind stand nearest the ground (the first web) and the web from the unwind stand located above the first web (the second web). The nomenclature used herein may not necessarily correspond to this convention sometimes used in the art.
  • both unwind stands 14, 16 may be considered “primary” unwind stands as opposed to “secondary” unwind stands.
  • a heavier, so-called “substrate” web is ordinarily referred to as the "primary” web taken from the primary unwind
  • a lighter web is ordinarily called the "secondary” web taken from a secondary unwind stand, at least in conjunction with operation ofthe dual or multiple station extruder system.
  • the first and second webs are preferably not ultimately laminated together according to the invention, at least in conjunction with operation of the dual or multiple station extruder system.
  • each web is, in essence, a primary web (according to trade nomenclature) and is taken from a primary unwind stand.
  • the first web 10 is provided as a substantially continuous web having two elongate, substantially parallel surfaces 20, 22 and a thickness therebetween which is small in comparison to the length and width of the surfaces.
  • One of the surfaces serves as a coating side 20 and the second as an underside 22.
  • such webs 10 have a basis weight of from about 11.39 g/m 2 (7 lbs / 3000 ft 2 ) to about 203.43 g/m 2 (125 lbs / 3000 ft 2 ) and a thickness or caliper of from about 0.0127 mm (0.5 mil) to about 0.254 mm (10 mils).
  • the basis weight is from about 24.42 g/m 2 (15 lbs / 3000) ft 2 to about 146.47 g/m 2 (90 lbs / 3000 ft 2 ) and the thickness ranges from about 0.0254 mm (1.0 mils) to about 0.2032 mm (8.0 mils).
  • preferred materials for the first web 10 are paper webs (including paperboard webs), polymer films (including oriented polymer films), metal foils, nonwoven fabrics, and two or more thereof supplied as a multi-ply web.
  • the second web 12 is provided as a substantially continuous web having two elongate, substantially parallel surfaces 24, 26 and a thickness therebetween which is small in comparison to the length and width of the surfaces, one of which serves as a coating side 24 and the second as an underside 26.
  • Such webs 12 have a basis weight of from about 11.39 g/m 2 (7 lbs / 3000 ft 2 ) to about 203.43 g/m 2 (125 lbs / 3000 ft 2 ) and a thickness or caliper of from about 0.0127 mm (0.5 mil) to about 0.254 mm (10 mils).
  • the basis weight is from about 24.42 g/m 2 (15 lbs / 3000 ft 2 ) to about 146.47 g/m 2 (90 lbs/3000 ft 2 ) and the thickness ranges from about 0.0254 mm (1.0 mil) to about 0.2032 mm (8.0 mils).
  • Preferred materials for the first substrate web 12 are paper webs (including paperboard webs), polymer films (including oriented polymer films), metal foils, nonwoven fabrics, and two or more thereof supplied as a multi-ply web.
  • the first and second webs 10, 12 may, if desired, be substantially identical, being formed from the same materials at substantially the same thicknesses and basis weights. However, the invention is not so limited and in certain preferred embodiments of the invention, the first and second substrates 10, 12 may differ substantially in material, weight, width, and / or thickness.
  • the locations ofthe unwind stands 14, 16 relative to the extrusion stations may vary in the practice of the invention.
  • the unwind stands 14, 16 are both situated adjacent from each other at the front of the extruder line and, as the first and second webs 10, 12 are unwound from their respective unwind stands 14, 16, the two webs are temporarily joined to one another along at least a portion of the length of the webs. This joining together is not permanent, however, in that the first web 10 is merely temporarily disposed on the second web 12 with the respective undersides 22, 26 of the webs contacting one another as seen in Fig. 2.
  • the interfacial friction against any lateral sliding of the webs with respect to one another will be suffcient to keep them aligned.
  • they may be temporarily adhered to one another by any of several methods. For instance, one or more edges of the two webs 10, 12 may be crimped together to hold the two webs 10, 12 together. The crimping may be accomplished at any point along the web path of wherein the webs 10, 12 are in contact with one another and prior to collection of the webs on a wind up stand using an edge crimping device 90.
  • an adhesive may be applied to one or both of the web undersides 22, 26.
  • the adhesive may be applied by a sprayer or other coating device 72.
  • the coating or spray need only be applied just prior to making roll change on the windup stand.
  • the webs 10,12 may also be joined by applying a static charge to one or both of the webs by a static charge device 30 prior to their contacting with each other.
  • the static charges imparted to the webs 10,12 may then be used to temporarily join the first web to the second web.
  • the static charge may preferably be applied across the entire width of the web or webs.
  • the extrusion coating itself may be used to temporarily join the webs 10, 12 along one or more edges.
  • the extrudate then tacks down the webs 10, 12 along the unaligned edge or edges.
  • Any one or a combination ofthe above methods may be used to join the webs 10, 12 depending on the types of substrates employed.
  • the temporarily joined webs are referred to collectively as the "composite web"32.
  • the first web 10 be coated in the first extrusion station as a single web. Thereafter the second web 12 may be laid on to the first web 10 prior to entering the second extrusion station. In this manner, the second web 12 as well as the first web 10 may be unwound coating side up, thereby eliminating the need to invert the webs after the first extrusion station.
  • first and second webs 10, 12 may be extrusion coated separately and thenjoined prior to being wound up together.
  • the webs may be would up separately without ever being joined together using dual windup stands at the end of the multi-station extruder.
  • first and second webs 10, 12 be temporarily joined as shown in Fig. 2 because this facilities collecting both finished webs on a single windup stand for later separation using a rewinder.
  • the temporary joining also allows automatic roll changes to be made at the windup stand at or near full line speed.
  • the webs 10, 12 need only be joined along a portion of the webs 10, 12.
  • At least one layer of polymeric coating is disposed on the respective coating sides of the first and second webs 20, 24.
  • the extruded coatings on the first and second webs 10,12 comprise a polymer selected from the group consisting of low density polyethylene (LDPE), polyolefin plastomers (POP), polyolefin elastomers (POE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), polypropylene (PP), ethylene methyl acrylate copolymer (EMA), ethylene butyl acrylate copolymer (EnBA), ethylene vinyl acetate copolymer (EVA), ethylene acrylic acid copolymer (EAA), ethylene methyl acrylic acid copolymer (EMAA), ionomoers such as SURLYN (which is understood to be a salt of poly (ethylene-co-methacrylic acid) available from Dupont), ethylene vinyl alcohol (EVOH), polyesters such as polyethylene terephthalate (PET), polyamides such as
  • LDPE low density polyethylene
  • POP polyolefin plastomers
  • POE polyolefin elastomers
  • LLDPE linear low density polyethylene
  • HDPE high density polyethylene
  • the thickness and coating weight of the polymer layer may also vary somewhat based on the particular application. However, the polymer coatings typically have a thickness of from about 5.334x10 -3 mm (0.21 mils) to about 0.0508 mm (2.0 mils) and a weight of from about 4.88 g/m 2 (3 lb/3000 ft 2 ) to about 47.20 g/m 2 (29 lb/3000 ft 2 ).
  • first web 10 and / or the second web 12 may be surface treated, such as with a flame treatment or in an electrical corona discharge device 70, in order to oxidize the surface of the web and provide improved adhesion of the polymer coating to the web.
  • the two webs 10, 12 are then conveyed to a first extrusion station 34 where the first polymer coating 36 is applied to the coating side of the first web 20 to provide a coated composite as illustrated in Fig. 3.
  • polymer is supplied in the form of pellets of the polymer which are fed into a hopper and melted and mixed with any additives to provide a fluid, relatively uniform melt-extrudible mass.
  • the molten material is then feed through an extrusion die 38 (seen in Fig. 6), and a resulting curtain of the extruded polymeric material 40 is extruded onto the composite web 32 as it passes through a nip in the extruder formed by a backup roll 42 and chill roll 44. Contacting with the chill roll 44 cools and solidifies the extrudate on the first coating side 20.
  • the polymer melt is extruded at a feed rate of about 226.8 kg/h (500 lb/ h) to about 453.6 kg/h (1000 lb / h) while the composite web is conveyed at a speed of about 228.6 m/min (750 ft/min) to about 457.2 m/min (1500 feet/min).
  • polymer feed rate, web width, and the web travel rate may be varied so as to provide thicker or thinner polymer coatings.
  • the composite web 32 is conveyed onward to a second extrusion station 50.
  • the first and second webs 10, 12 of the composite web 32 may be inverted or otherwise reoriented so that the second web 12 is properly aligned for coating at the second extrusion station 50. This may be accomplished using a set of turning bars 74.
  • the second web coating side 24 is extrusion coated with a second polymer coating 52 as shown in Fig. 4.
  • the molten polymer (along with any desired additives) is then feed through a second extrusion die and a curtain of the polymer is extruded onto the composite web as it passes through a nip in the extruder formed by a backup roll and a chill roll.
  • Contacting with the chill roll cools and solidifies the second polymer coating extrudate 52 forming a layer of polymeric coating on the composite web 32.
  • the second polymer melt is also extruded at a feed rate of about 226.8 kg/h (500 lb/ h) to about 453.6 kg/h (1000 lb/h) while the web is conveyed at a speed of about 228.6 m/min (750 ft/min) to about 457.2 m/min (1500 feet / min) to provide a polymer coating 52 having a thickness of about 0.0127 mm (0.5 mils).
  • the two webs 10, 12, now each extrusion coated with a polymeric layer, may be collected.
  • the webs 10, 12 may be separated from one another in line as seen in Fig. 5 and collected on separate wind up rolls directly after the second extrusion coating.
  • the first and second webs 10, 12 be initially wound up together as a composite roll 54.
  • the webs are preferably temporarily joined together, typically along the edges of the webs 10, 12.
  • the composite roll 54 may then be processed on a rewinder apparatus 80, shown in Fig. 7, which includes a trimmer 82 which cuts away the joined edges thereby separating the finished webs and allowing the webs 10,12 to be individually wound up on two separate windup rolls 84; 86.
  • a dual or tandem station extruder may be used to approach or fulfill its rated capacity while applying one-side only coatings to substrate webs.
  • the method allows the production speed of a dual extruder to be effectively doubled when used for one-side only coatings since two such products may now be extrusion-coated at once.
  • the two substrates and their respective coatings may be the same.
  • the invention may thus be used to dramatically increase the rate of production of a single type of extrusion coated substrate.
  • the substrates and / or their polymer coating may also different.
  • the invention provides a means to produce small batches of relatively low-volume coated substrate without halting production of much larger batches of a higher selling-volume product.
  • Two webs of kraft paper each having a basis weight of about 51.27 g/m 2 (31.5 lbs / 3000 ft 2 ) and a caliper of about 0.0635 mm (2.5 mils) and having widths of about 80.645 cm (31.75 inches) (the first web) and 86.36 cm (34 inches) (the second web) respectively were unwound from separate rolls and conveyed to an extrusion coating system by a series of rollers and idlers. The two webs so combined were passed through a first extrusion station.
  • a supply oflow density polyethylene EASTACOAT 6838-850P available from Eastman Chemical Co. of Longview, TX was heated to a temperature of about 321°C (610 °F) to provide a supply of molten extrudate.
  • the molten extrudate was then feed through an extrusion die at a feed rate of about 113.4 kg/h (250 lb/h) to coat the exposed side of the first paperweb as it moved through the extrusion station.
  • the extrudate was cooled by contacting with a chill roll forming a polymer coating over the kraft paper of the first web.
  • the polymer coating weight was about 3.63 kg/riesmaschine (8 lbs /ream).
  • a second extrusion coating was then applied to the second substrate web.
  • a second supply of low density polyethylene was heated to a temperature of about 321°C (610 °F) to provide a supply of molten extrudate.
  • the molten extrudate was then feed through an extrusion die at a feed rate of about 113.4 kg/h (250 lb/h) to coat the second paperweb side of the temporary composite as it moved through the second extrusion station.
  • the extrudate was cooled by contacting with a chill roll to form a polymer coating over kraft paper of the second web.
  • the polymer coating weight formed on the second web was also about 3.63 kg/riesmaschine (8 lbs/ream).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating Apparatus (AREA)

Claims (41)

  1. Procédé de revêtement par extrusion de plusieurs bandes continues dans un système d'extrusion contenant plusieurs stations d'extrusion comprenant :
    l'envoi d'une première bande continue et d'une deuxième bande continue dans le système d'extrusion, chaque bande continue ayant une face de revêtement ;
    le transport de la première bande continue vers une première station d'extrusion dans le système d'extrusion et l'extrusion d'un premier revêtement polymère sur la face de revêtement de la première bande continue au niveau de la première station d'extrusion ;
    la disposition de la deuxième bande continue sur la première bande continue pour former un composite temporaire ;
    le transport de la deuxième bande continue vers une deuxième station d'extrusion dans le système d'extrusion et l'extrusion d'un deuxième revêtement polymère sur la face de revêtement de la deuxième bande continue au niveau de la deuxième station d'extrusion ; et
    la séparation des première et deuxième bandes continues du composite temporaire.
  2. Procédé selon la revendication 1 dans lequel les premier et deuxième substrats de bande continue comprennent le même matériau substrat.
  3. Procédé selon la revendication 1 dans lequel les premier et deuxième substrats de bande continue comprennent différents matériaux substrats.
  4. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues sont revêtues par extrusion avec le même type de polymère.
  5. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues sont revêtues par extrusion avec différents types de polymères.
  6. Procédé selon la revendication 1 dans lequel le premier revêtement polymère comprend un polymère choisi dans le groupe comprenant le polyéthylène à basse densité (LDPE), le plastomère de polyoléfine (POP), l'élastomère de polyoléfine (POE), le polyéthylène linéaire à basse densité (LLPDE), le polyéthylène à haute densité (HDPE), le polypropylène (PP), le copolymère d'éthylène et d'acrylate de méthyle (EMA), le copolymère d'éthylène et d'acrylate de butyle (EnBA), le copolymère d'éthylène et d'acétate de vinyle (EVA), le copolymère d'éthylène et d'acide acrylique (EAA), le copolymère d'éthylène et d'acide méthylacrylique (EMAA), les ionomères, le copolymère d'éthylène et d'alcool vinylique (EVOH), les polyesters tels que le polyéthylène téréphtalate (PET), les polyamides (PA), et les mélanges de deux ou davantage de ceux-ci.
  7. Procédé selon la revendication 1 dans lequel le deuxième revêtement polymère comprend un polymère choisi dans le groupe comprenant le polyéthylène à basse densité (LDPE), le plastomère de polyoléfine (POP), l'élastomère de polyoléfine (POE), le polyéthylène linéaire à basse densité (LLPDE), le polyéthylène à haute densité (HDPE), le polypropylène (PP), le copolymère d'éthylène et d'acrylate de méthyle (EMA), le copolymère d'éthylène et d'acrylate de butyle (EnBA), le copolymère d'éthylène et d'acétate de vinyle (EVA), le copolymère d'éthylène et d'acide acrylique (EAA), le copolymère d'éthylène et d'acide méthylacrylique (EMAA), les ionomères, l'alcool vinyl éthylène (EVOH), les polyesters tels que le polyéthylène téréphtalate (PET), les polyamides (PA), et les mélanges de deux ou davantage de ceux-ci.
  8. Procédé selon la revendication 1 dans lequel la première bande continue est choisie dans le groupe comprenant les feuilles de papier continues, les films polymères, les non-tissés, les feuilles de métal et les feuilles continues multicouches comprenant deux ou davantage de ceux-ci.
  9. Procédé selon la revendication 1 dans lequel la deuxième bande continue est choisie dans le groupe comprenant les feuilles de papier continues, les films polymères, les non-tissés, les feuilles de métal et les feuilles continues multicouches comprenant deux ou davantage de ceux-ci.
  10. Procédé selon la revendication 1 dans lequel la première bande continue possède une épaisseur comprise entre environ 0,0127 mm (0,5 mils) et environ 0,254 mm (10 mils) et un poids de base compris entre environ 11,39 g/m2 (7 Ibs/3 000 pi2) et environ 203,43 g/m2 (125 Ibs/3 000 pi2).
  11. Procédé selon la revendication 1 dans lequel la deuxième bande continue possède une épaisseur comprise entre environ 0,0127 mm (0,5 mils) et environ 0,254 mm (10 mils) et un poids de base compris entre environ 11,39 g/m2 (7 Ibs/3 000 pi2) et environ 203,43 g/m2 (125 lbs/3 000 pi2).
  12. Procédé selon la revendication 1 comprenant également l'étape d'inversion de la bande continue composite avant l'extrusion du deuxième revêtement polymère.
  13. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues revêtues sont initialement enroulées ensemble sur un seul bobinoir puis séparées.
  14. Procédé selon la revendication 13 dans lequel les première et deuxième bandes continues revêtues sont temporairement jointes ensemble le long d'au moins un bord et sont séparées par rognure du bord joint et enroulement des première et deuxième bandes continues sur des cylindres d'enroulement séparés.
  15. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues revêtues sont séparées et collectées sur des cylindres d'enroulement séparés directement après l'extrusion du deuxième revêtement polymère.
  16. Procédé selon la revendication 1 dans lequel le premier revêtement polymère comprend une coextrusion d'une pluralité de revêtements polymères.
  17. Procédé selon la revendication 1 dans lequel le deuxième revêtement polymère comprend une coextrusion d'une pluralité de revêtements polymères.
  18. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues sont revêtues sur leurs faces de revêtement respectives avant d'être séparées.
  19. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues du composite temporaire sont revêtues sur leurs faces de revêtement respectives l'une après l'autre dans les première et deuxième stations de revêtement.
  20. Procédé selon la revendication 1 dans lequel les première et deuxième stations d'extrusion comprennent une partie de la même extrudeuse et les faces de revêtement respectives des première et deuxième bandes continues sont revêtues sensiblement simultanément dans la même extrudeuse.
  21. Procédé selon la revendication 1 dans lequel les première et deuxième stations d'extrusion comprennent une partie de la même extrudeuse et les faces de revêtement respectives des première et deuxième bandes continues sont revêtues l'une après l'autre dans la même extrudeuse.
  22. Procédé selon la revendication 1 dans lequel les première et deuxième bandes continues sont en contact l'une avec l'autre dans le composite temporaire.
  23. Procédé selon la revendication 1 dans lequel une ou deux des première et deuxième bandes continues sont sensiblement non revêtues sur leur face de revêtement avant l'extrusion du revêtement polymère sur celles-ci.
  24. Procédé selon la revendication 1 dans lequel une ou deux des première et deuxième bandes continues contiennent sur leur face de revêtement une ou plusieurs couches d'un ou plusieurs matériaux revêtus sur celles-ci avant l'extrusion du revêtement polymère sur celles-ci.
  25. Procédé de revêtement par extrusion de plusieurs bandes continues dans un système d'extrusion contenant plusieurs stations d'extrusion selon la revendication 1 comprenant également :
    l'envoi d'une première bande continue et d'une deuxième bande continue dans une première station d'extrusion du système d'extrusion, chaque bande continue ayant une face de revêtement et une face inférieure, les bandes continues étant agencées l'une par rapport à l'autre de façon à former un composite temporaire dans lequel les faces inférieures respectives des bandes continues se font face et leurs faces de revêtement respectives sont dirigées vers l'extérieur, espacées l'une de l'autre ;
    l'extrusion d'un premier revêtement polymère sur la face de revêtement de la première bande continue du composite au niveau de la première station d'extrusion ;
    l'envoi du composite vers une deuxième station d'extrusion après l'extrusion du premier revêtement polymère sur celui-ci ;
    l'extrusion d'un deuxième revêtement polymère sur la face de revêtement de la deuxième bande continue du composite au niveau de la deuxième station d'extrusion ; et
    la séparation des première et deuxième bandes continues revêtues par extrusion du composite.
  26. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues comprennent le même matériau de bande continue.
  27. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues comprennent différents matériaux de bande continue.
  28. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues sont revêtues par extrusion avec le même type de polymère.
  29. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues sont revêtues par extrusion avec différents types de polymère.
  30. Procédé selon la revendication 25 dans lequel le premier polymère est choisi dans le groupe comprenant le polyéthylène à basse densité (LDPE), le plastomère de polyoléfine (POP), l'élastomère de polyoléfine (POE), le polyéthylène linéaire à basse densité (LLPDE), le polyéthylène à haute densité (HDPE), le polypropylène (PP), le copolymère d'éthylène et d'acrylate de méthyle (EMA), le copolymère d'éthylène et d'acrylate de butyle (EnBA), le copolymère d'éthylène et d'acétate de vinyle (EVA), le copolymère d'éthylène et d'acide acrylique (EAA), le copolymère d'éthylène et d'acide méthylacrylique (EMAA), les ionomères, l'alcool vinyl éthylène (EVOH), les polyesters tels que le polyéthylène téréphtalate (PET), les polyamides (PA), et les mélanges de deux ou davantage de ceux-ci.
  31. Procédé selon la revendication 25 dans lequel le deuxième revêtement polymère comprend un polymère choisi dans le groupe comprenant le polyéthylène à basse densité (LDPE), le plastomère de polyoléfine (POP), l'élastomère de polyoléfine (POE), le polyéthylène linéaire à basse densité (LLPDE), le polyéthylène à haute densité (HDPE), le polypropylène (PP), le copolymère d'éthylène et d'acrylate de méthyle (EMA), le copolymère d'éthylène et d'acrylate de butyle (EnBA), le copolymère d'éthylène et d'acétate de vinyle (EVA), le copolymère d'éthylène et d'acide acrylique (EAA), le copolymère d'éthylène et d'acide méthylacrylique (EMAA), les ionomères, l'alcool vinyl éthylène (EVOH), les polyesters tels que le polyéthylène téréphtalate (PET), les polyamides (PA), et les mélanges de deux ou davantage de ceux-ci.
  32. Procédé selon la revendication 25 dans lequel la première bande continue est choisie dans le groupe comprenant les feuilles de papier continues, les films polymères, les non-tissés, les feuilles de métal et les feuilles continues multicouches comprenant deux ou davantage de ceux-ci.
  33. Procédé selon la revendication 25 dans lequel la deuxième bande continue est choisie dans le groupe comprenant les feuilles de papier continues, les films polymères, les non-tissés, les feuilles de métal et les feuilles continues multicouches comprenant deux ou davantage de ceux-ci.
  34. Procédé selon la revendication 25 dans lequel la première bande continue possède une épaisseur comprise entre environ 0,0127 mm (0,5 mils) et environ 0,254 mm (10 mils) et un poids de base compris entre environ 11,39 g/m2 (7 lbs/3 000 pi2) et environ 203,43 g/m2 (125 Ibs/3 000 pi2).
  35. Procédé selon la revendication 25 dans lequel la deuxième bande continue possède une épaisseur comprise entre environ 0,0127 mm (0,5 mils) et environ 0,254 mm (10 mils) et un poids de base compris entre environ 11,39 g/m2 (7 lbs/3 000 pi2) et environ 203,43 g/m2 (125 Ibs/3 000 pi2).
  36. Procédé selon la revendication 25 comprenant également l'étape d'inversion de la bande continue composite avant l'extrusion du deuxième revêtement polymère sur la face de revêtement de la deuxième bande continue du composite.
  37. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues revêtues sont enroulées ensemble sur un seul bobinoir avant d'être séparées.
  38. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues revêtues sont temporairement jointes ensemble le long d'au moins un bord et sont séparées par rognure du bord joint et enroulement des première et deuxième bandes continues sur des cylindres d'enroulement séparés.
  39. Procédé selon la revendication 25 dans lequel les première et deuxième bandes continues revêtues sont séparées et collectées sur des cylindres d'enroulement séparés après l'extrusion du deuxième revêtement polymère.
  40. Procédé selon la revendication 25 dans lequel le premier revêtement polymère comprend une coextrusion d'une pluralité de revêtements polymères.
  41. Procédé selon la revendication 25 dans lequel le deuxième revêtement polymère comprend une coextrusion d'une pluralité de revêtements polymères.
EP02801725A 2001-10-16 2002-10-16 Procede de revetement par extrusion de plusieurs bandes continues Expired - Lifetime EP1436136B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US978392 1997-11-25
US09/978,392 US6656401B1 (en) 2001-10-16 2001-10-16 Method for extrusion coating multiple webs
PCT/US2002/032889 WO2003033237A1 (fr) 2001-10-16 2002-10-16 Procede de revetement par extrusion de plusieurs bandes continues

Publications (3)

Publication Number Publication Date
EP1436136A1 EP1436136A1 (fr) 2004-07-14
EP1436136A4 EP1436136A4 (fr) 2004-10-27
EP1436136B1 true EP1436136B1 (fr) 2006-08-23

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EP02801725A Expired - Lifetime EP1436136B1 (fr) 2001-10-16 2002-10-16 Procede de revetement par extrusion de plusieurs bandes continues

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US (2) US6656401B1 (fr)
EP (1) EP1436136B1 (fr)
AT (1) ATE337159T1 (fr)
CA (1) CA2463763C (fr)
DE (1) DE60214211D1 (fr)
WO (1) WO2003033237A1 (fr)

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Also Published As

Publication number Publication date
WO2003033237A1 (fr) 2003-04-24
EP1436136A1 (fr) 2004-07-14
ATE337159T1 (de) 2006-09-15
US20040183223A1 (en) 2004-09-23
DE60214211D1 (de) 2006-10-05
US6656401B1 (en) 2003-12-02
CA2463763A1 (fr) 2003-04-24
CA2463763C (fr) 2007-10-02
EP1436136A4 (fr) 2004-10-27
WO2003033237B1 (fr) 2004-05-21

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